Graco 231-032 A Series Datasheet

INSTRUCTIONS/ PARTS LIST Rev 307-758 B
SUPERSEDES A
This manual contains IMPORTANT
WARNINGS and INSTRUCTIONS
READ AND RETAIN FOR REFERENCE
120 VAC, 15 Amp
ULTRA"500 AIRLESS PAINT SPRAYER
2750 psi (1% bad MAXIMUM WORKING PRESSURE
Model 231432, Series A
Basic, without hose, gun, spray tip kitor tip
Model 231-041
Includes Sprayer Model231-034.hose,gun,RAC 111
spray tip kit, and spray tip of choice.
Model 22049, Series B
Same as 231-041 except is CSA certified
PATENT NO. 4.r)7.610
PATENTED 1963. CANADA
BREVETE 1984
FOREIGN PATENTSPENDING
INDEX
Warnings ................................ 2, 3
Avertissement .......................... 4. 5
Advertencia ...... ....................... 6, 7
Introduction ......... ....................... 8
Operation .................................. 10
Shutdown
& Care ...... ... ... ... .. .... .. .11
Flushing Guidelines
...................... 12
Troubleshooting Guide
............. 13-20
Spin Test
...... . .. .. ... ... ... ... . ... ..... .. .19
Bridge Test
................................ 20
Repair Section Index .................... 21
Parts List Et Drawings
Sprayer
............................. 32, 33
How To Order Replacement Parts.33
Pressure Control
...................... 34
Circuit Board ........................... 35
Technical Data ................
Back Cover
Warranty
.......................
Back Cover
setup.
.. .. .. .. . . .. . .. .. .. .. ... ... .. .... . , .. . . .9
WARNING
Never use 1,l.l-trichloroethane, methylenechloride, other halogenated hydrocarbon solvents orfluidscontaining
such solventsinthisequipment. Suchuse could resultin
a serious chemical reaction,withthe possibility of explo-
sion, which could cause death, serious bodily injury and/or substantial property damage.
Consult your fluid suppliers to ensure that the fluids being used
are compatiblewith aluminum and zinc parts.
GRACOINC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1444
@COPYRIGHT 1986 GRACO INC.

WA RPJING
HIGH PRESSURE SPRAY CAN CAUSE SERIOUS INJURV.
FOR PROFESSIONAL USE ONLY. OBSERVEALL WARNINGS.
Read and understand
all instruction manuals before operating equipment.
FLUID INJECTION HAZARD
General Safety
This equipment generates very highfluidpressure. Sprayfrom
the gun,leaksor rupturedcomponentscaninject fluid
throughyourskinend into yourbodyandcauseextremely
serious bodily injury, including the need for amputation. Also,
fluid injected orsplashed into
the eyes or on the skin can
cause serious damage.
NEVER point the spray gun
at anyone or at any part of the
try to "blow back" paint; this isNOT an air spray system.
body. NEVER put hand or fingers over the spray tip: NEVER
ALWAYS have the tip guard in place
on the spray gun when
spraying.
before cleaningorremoving the spray tip orservicing any
ALWAYS .follow
the Pressure Rellef Procedure. below,
system equipment.
NEVER try to stop or deflect leakswith your hand or body.
before each use.
Be sureequipmentsafetydevicesareoperatingproperly
Medical Alert-Airless Spray
Wounds
If any fluid appears to penetrate your skin, get EMERGENCY
MEDICAL CARE AT ONCE.
DO NOTTREAT AS A
SIMPLECUT. Tell the doctor exactly
what fluid was injected.
Note to Physlclan: Injection in the skin is a traumatic in-
jury. It Is Important to treat the injury surgically ns soon
es posslble. Do not delay treatment to rasearch toxicity.
direct& into the blood stream. Consultation with e plastic
Toxicily is e concern wi?h some exotic coatings injected
surgeon or reconstructivehandsurgeon maybeadvisable.
Spray Gun Safety Devices
Be sure a11 gun safety devices are operating properly before
each
us8. Do not remove or modifyany part of the gun; this
cancause
a malfunction and result in serious bodily injury.
Safety
Latch
Whenever you stop spraying, even fora moment, always set
the gun safety latchinthe closed or "safe" position, making
the gun inoperative. Failureto
set the safetylatchcan resultin
accidental triggering of the gun.
Diffuser
The gun diffuserbreaks up spray and reducesthe risk of fluid
injection when thetip isnot installed.Check diffuser operation
regularly.Follow the Pressure RellefProcedure. below,
thenremovethespray tip.Aimthegun into
a metalpail,
holding the
gun firmly to the pail. Using the lowest possible
to an irregular stream. replace the diffuser immediately.
pressure, trigger the gun.Ifthe fluid emitted
is notdiffusedin-
Tip Guard
spraying. The tip guard alerts youto the fluid injectionhazard
ALWAYS have the tip guard in place
on the spray gun while
and helps reduce,butdoes not prevent, the risk of accidental-
ly placing your fingers
or any part of your body close to the
spray tip.
Trigger Guard
Alwayshavethetrigger guardinplace
on the gun when spray-
ingto reduce the risk of accidentally triggering the gunif
it is
dropped or bumped.
Spray
Tip Safety
thespray tip clogs while spraying, engage
the gun safety latch
Use extreme caution whencleaning or changing spraytips. If
immediately.ALWAYS followthe. Pressure RellefPro-
cedure and then remove the spraytip to clean
it.
fully relieved and the gun safety latch is engaged.
NEVER wipe
off build-uparoundthe spray tip untilpressureis
Pressure Relief Procedure
To reducethe risk of serious bodily injury, includingfluid injection,splashing fluidor solvent intheeyes or
on the skin, or injury
from moving partsor electric shock, alwaysfollow this procedure whenever you shut off thesprayer, when checkin or servic-
ingany part
of theqxaysystem, when installing, cleaning or changing spray tips,and whenever you stopspraying.(fl) Engage
the gun safety latch. (21 Turn theON/OFF switchto OFF. 131 Unplug the power supply cord. (4) Disengage the gunsafay latch.
(5) Hold a metal partof the gun firmlytotheside of a grounded metal pail, and trigger the guntorelieve pressure. 161 Engagethe
gun safety latch.
(71 Open the pressure relief valve, having a container readytocatchthe drainage. (8)Leavethe pressure relief
valve open until you are ready to spray again.
If you suspect rhat the spray tip or hose is complete+ dogged, or fhatpressure hasnor been fulty relievedafter following the
stepsabove, VERY SLOWLY loosen thetip guard retainingnut or hose endcouplingand relieve pressure gradually,then loosen
completely. Now clear the tip
or hose.
/ ,' *'
TURN SWITCH TO OFF
LATCH UNPLUG CORD
OPENPRESSURE
RELIEFVALVE
2 307-768

> >,.
. ..
...
. ..
EQUIPMENT MISUSE HAZARD
General Safety
Any misuse of the spray equipment or accemries, such as
overpressurizing, modifying parts,using incompatible
chemicalsandfluids,orusingwornordamagedparts,csn
cause themto rupture and resultinfluidinjection. splashingin
the eyes or onthe skin, or other serious bodily injury, fire, ex-
plosionor property damage.
NEVERalter or modify any part of this equipment: doing
so
could cause it to malfunction.
CHECK
all sprayequipmantregularlyandrepairorreplace
worn or damaged parts immediately.
Alwayswearprotective eyewear,glovesand clothing as
recommendedby the fluid and solvent manufacturer.
SystemPressure
This sprayercandevelop 2750 psi /795 bar) MAXlMUM
WORKING PRESSURE. Be surethat all sorav muiomentand
accessorik are~ritedto withstandthe'maximumworking
pressure ofthis sprayer.
DO NOT exceed the maximumwork-
svstem.
ingpressure of anycomponentoraccessoryused in the
Fluid and Solvent Compatibllity
Alwaysread the fluid andsolventmenufecturer'sliterature
More using themin this sprayer.
~ ~ ~~~
HOSE SAFETY
High pressure fluid in the hoses can be very dangerous.If the
hose develops
a leak, split or rupturedue to any kindof wear,
damage or misuse,the highpressure sprayemittedfrom
it can
cause
a fluid injectioninjury or other serious bodily injury or
propertydamage.
ALL FLUID HOSES MUST HAVESPRING GUARDS
ON
BOTH ENDS1 The spring guards help protect thehose from
kinks or bendset or closeto the couplingwhich can result
in
hose rupture.
TIGHTEN allfluid connections securely before each use. High
pressure fluid candislodge
a loose coupling or allowhigh
pressure spray to be emitted fromthe coupling.
tirehosefor cuts. leaks, abrasion,bulgingcover. or damage or
NEVER
use a damaged hose. Before each use, check the en-
exist. replace the hose immediately.
DO NOT try to recouple
movement of the hose couplings. If any of these conditions
high pressure hose or mend
it withtape or any other device.A
repaired hose cannot contain the high pressure fluid.
hosestomove equipment.
Do not usefluidsorsolvents which
HANDLEAND ROUTEHOSESCAREFULLY.
Do not pull on
are notcompatiblewith the inner tube and coverof the hose.
DO NOTexposeGracohose to temperaturesabove lWF
(82"CI or below -40°F (40O"Cl.
Hose Groundin Continuity
Proper hosegrounkgcontinuityiswntialto maintaininga
rounded spray system.Check the electrical resistanceofyour
tagon
it which specifies the maximum electrical resistance,
uid hoses et least once
a
week. Ifyour
hose does nothave a
contact the hose supplier or manufacturer for the maximum
resistance limits. Use
a resistancemeter in theappropriate
range for your hose to check the resistance. If the resistance
exceeds the recommended limits, replace
it immediately. An
ungrounded or poorly grounded hose canmake your system
hazardous.
Also readFIRE OR EXPLOSION HAZARD.
w
FIRE OR EXPLOSION HAZARD
through the pumpend hose. If every part of the spray equip-
Static electricity is created by the high velocity flow of fluid
ment
is not properly grounded, sparking may occur, and the
systemmaybecomehazardous.Sparkingmayalsooccur
when plugginginor unplugging
e power supply cord. Sparks
can ignite fumes from solventsand the fluid beingsprayed,
dust particles and other flammable substances, whether you
are spraying indoors or outdoors,and can cause
a fire or ex-
plosionandseriousbodilyinjuryandpropertydamage.
Always plug the.sprayer into an outlet at leest
20 feet I6 m)
away from the sprayer and the spray area. Do not plug in or
any chance of igniting fumes still inthe air.
unplugany power supply cordsinthespray areawhen thereis
If youexperienceany static sparking or even a
sli ht shock
whileusingthisequipment,STOP SPRAYING IMMEDI-
ATELY. Checktheentire systemforproper grounding.
Do not
use the system againuntilthe problemhas beenidentifiedand
corrected.
Grounding
To reduce the risk of static sparking, ground the sprayer and
all other spray equipment used or located in the sprayarea.
structionsfor your area and type of equipment.
BE SURE to
CHECK yourlocalelectricalcodefordetailedgrounding in-
ground
all of this spray equipment:
1.
2.
3.
4;
5.
6.
7.
Sprayer: plug the power supply cord,or extension cord,
each equippedwithan undamaged three-prong plug,into
a properly grounded outlet. Do not use en adepter.All ex-
tension cords musthave three wires and
be rated for 15
amps.
Fluid hoses: use only grounded hoseswith a maximumof
5M)feet (150 m)combined hose lengthtoensure ground-
ing continuity. Refer to
Hose Groundlng Continulty.
Spray
gun: obtaingroundingthroughconnection to a
properly groundedfluid hose and sprayer.
Objectbeingsprayed: according to
lml code.
fluid supply container: according
to local code.
AI1 solventpails used when flushing, according to local
code. Useonly metelpails, which are conductive.
Do not
placethe pail on a non-conductive surface, suchas paper
or cardboard, which interrupts the grounding continuity.
ing pnrssura, always hold ametalpartof thegun firmly to
To maintaingroundingcontinuiry when flushingorreliev-
the side
of agroundedmetalpail, then trigger the gun.
Flushing Safety
Reducethe risk of injectioninjury, static sparking, or splashing
of this menuel.Pollow thePressure RellefProcedure on
by fqllowing the specific flushing procedure given onpage 12
page
4, and remove the spray tip before flushing. Hold a metal
part of the gun firmly to the side of a metal pail and use the
lowest possible fluid pressure during flushing.
MOVING PARTS HAZARD
Movingpartscanpinchoramputateyourfingersorother
body parts. KEEPCLEAR of movingpartswhenstartingor
operating the sprayer. Unplugthe sprayer.and follow the
Pressure Rellef Procedure onpage
2, beforecheckingor
servicingany part of the sprayer to prevent it from starting
accidentally.
IMPORTANT
ticularly the General Standards, Part 1910, and the Construction Standards,
Part 1926-should be consulted.
United States Government safety standards
have beenadopted under the Occupational Safetyand HealthAct. These standards-par-
307-758 3

A VER TIS
La pulvdrisation A haute pression peu blessures trhs graves.
RBserv6 exclusivement A I'usage professionnel. Observer toutes les consignes de s6curit6.
Bien lira et bien comprendre tous les manuals d'instructlons avant d'utiliser le matbriel.
RlSQUES D'INJECTION
Consignes gBnBrales de sBcuritB
Cet appareil produit unfluide B trbhaute pression. Le fluide
fuites
ou de ruptures peutphetrer sous la peau ou B I'interieur
pulv4risbpar
le pistolet ou le fluide sous pression provenant de
du corps
et entrainerdes blessurestrhgraves, voir m6me une
amputation. Meme
sans &re sous pression, le fluide Bclabous-
ant
ou entrant dens Ias yeux peutaussientrainerdes
Massurea graves.
NE JAMAIS pointer
le pistoletvers quelqu'un ou vers unepar-
tie quelconque du corps. NE JAMAIS mettre la main ou 188
doigts sur I'ajutage du pulv6risateur. NE JAMAIS essayer de
"refouler"
la peinture. Cet appareil Nest PAS uncompreSSBur
pneurnatique.
TOUJOURS garder
la protectionde I'ajutage en place sur le
pistolet pendant la pulv6risation.
TOUJOURS obsenrer
la March B Sulvra pour DBtendre la
Pressiondonneeplusloin, avant denettoyer ou d'enlever
I'ejutage dupulverisateur, ou d'effectuer un travailquelcon-
que sur une partie de I'appareil.
NE JAMAIS essayer
d'arr&er ou de d4viir les fuites avec la
main ou le corps.
Avant chaque utilisation, biens'assurer que
Ies dispositifsde
s4curit4 fonctionnent correctemant.
Soins m4dicaux
En cas de penetration de fluide sous le paau: DEMANDER
IMMEDIATEMENTDES
SOINS MEDICAUX
D'URGENCE.NE PAS SOIGNERCETTE ELESSURE
COMME UNE SIMPLE COUPURE.
Avls au madecln: La pdndtrationdes fluides sous la paeu
esr
un traumarisme. II est Importantdetraltar
chlrurglcalement
cette blesaureImm4dlatament. Ne
pas retarder le treitementpour effectuer das recherches sur
la mx". Certeins revdtements exotiques sontdengereuse-
sang.
I1 est souhaitable de consulter un chirurgien esthdtique
menr toxiques quendissont injectds directement dens
le
ou un chirurgienspdcielisd dans la reconstructiondes mains.
Dispositifs de sBcurit6 du pistolat
enlever ni modifier une partie quelconque du pistolet; ceci ris-
queraitd'entralnerunmauvais fonctionnement
et des
blessures graves.
Verrou de securitd
A chaquefois que
I'on s'arr8te de pulvbriser, mbme s'il s'agit
d'un courtinstant,toujoursmettre
le verroude sewrite du
pistolet sur
le position "fermk" ou "sbcurit4" 1"safe") pour
empkher
le pistolet de fonctionner. Si le verrou de &curite
n'est pas mis, le pistolet peut se d4clencher accidentellement.
Voir la Fig.
3.
Diffuser
quesd'injectionaccidentellequandI'aiutage n'est pasen
Le diffuseurdu pistolet sert B diviser le jet et 13 reduire 189 ris-
place. Vbrifier
la fonctionnement du diffuseur rbgulibrement.
Pour
cette v&ification, detendre la pression en ObseNant 19
loin puis enlever I'ajutage du pulv6risateur. Pointer le pistolet
Marche
A Suivre pour DBtendre la Pressiondonnb plus
dens unseeu
en metal, en le maintenant fermement contre le
wau. Puis,en utilisant la pression la plus feible possible, ep-
puyer sur
le gachette du pistolet. Si le fluide projeten'estpas
diffuse sous formedejet irrbgulier, remplacer imm4diatement
le diffuseur.
Protection
de /%jute e
TOUJOURS maintenir
B e protectionde I'ajUtage en place Sur le
tion de I'ajutage anire I'anention sur 18s risques dhjection et
pistolet du pulverisateurpendant la pulv6risation. La PrOteC-
contribue
B reduire, mais n'4vite pas le risque, que Ies doigts
ou une partie quelconque du corps ne passent accidentelle-
ment B proximite immediatede I'ajutage du pulv4risateur.
Consignesde
skurite concarnantI'ajutaga du
pulv4risateur
remplacementdesajutagesdupuhrbrisateur.
Si I'ajutage sa
Faire ear8mement attention B I'occasion du nettoyage ou du
bouchependant
la pulv6risation,mettreimmediatement le
verroude skurite du pistolet. TOUJOURSbienobserver la
Marche B Suivre pour DBtendre la Pressionpuis BnleVBr
I'ajutage du pulverisateur pour le nettoyer.
NE JAMAIS essuyer caqui s'est accumul6 autour de I'ajUta9e
tomb&
et que le verrou de securitb du pistoletne soit engage,
du pulv4risateur avant que
la pression ne soit completement
Avant cheque utilisation, bien
s'assure quetous Ies dispositik
de &curite du pistoletfonctionnentcorrectemant. Nepas
,
\
Marche A Suivre pour DBtendre la Pression
Pourreduire
Ies riGues deblessureagraves, y compris Ies blessurespar injection de fluiie ou celles tau+ perdes
Bclaboussures dens
Ies yeux ou sur la peau, des pieces en mouvement ou par Blectrocution. toujours bien obsenrer.cette marche
B suivre B chaquefois que l'on arrete le pulv6risateur. B I'occasion de la verificationou de la reparation d'une piece de I'appareil
de pulv6risation.
B I'ocasion de I'installation. du nettoyage ou duremplacement des ejutagea et d'une maniere gendrala B cha-
que arr8t. 1) Engager le verroude skurite du pistolet. 21 MettreI'interrupteur Marche-Arrbt sur ARRET 1"OFF"). 3) Debrancher
le cordon d'alimentation. 4) DBsengager le vermude &curite du pistolet. 5) En maintenant une partie m4tallique du pistolet
fermentappuybcontre
le c6t4d'un seau en m4tal. appuyet sur la gachenedupistolet pour lib4rer la pression. 61 Engager le
verrou de skurite du pistolet. 7) Ouvrir la soupape de s4curite en prenant soin d'avoir un recipient pr8t B rkupbrer le liquide.
8) hisser la soupape ouvena jusqu'h ce que !a pulverisateursoit de nouveau pret B &re utilis6.
SiI'on soupmnne
qua I'ejutage du pulv&iseteur ou /a ruvau estmmplbtement bouchd, ou qua lapressionn'epas Btd complbte-
men?
libdnh, aprdsavoirproddd aux ophtionsci-dessus, desserrer TRES LENTEMENT I'Bcrou de retenue de la protectlonde
, l'ajutege w le raccorddu bout du tuysuetlib4rer progressivement le pression, puis terminer ledesserrage. Onpeut maintenant
deboucher I'a'uta
e ou le tuyeu.
I
1 2 3 4.5.6 7
4 307-758

RISQUES EN CAS DE MAUVAISE UTlLlSATlON DU MATERIEL
Cansignesg4nBraies de s4curit4Pression
Toute utilisation anormale de I'appareil de pulvdrisation ou des
accessoires comme, par exemple, la mise
sous una pression Ce pulvbrisateur peut produire un PRESSIONMAXIMUM
DE
TRAVAIL 195 bar (2750 lb/po. 2 1. S'assurerque tous Ies
excessive, Ies modifications de pibces, I'utilisation de produits
chimiquesetdematibresincompatibles et I'utilisation de Blbmentsdu pulv4risateuret
ses accessoires sontconcus pour
resister
B la pression maximum de travail de ce pulvbrisateur.
pieces us& ouabimbspeutcauser des &gats B I'appareil ou ' NE PAS depesserla pression maximum de travail d'aucun des
des ruptures de pibceset entrainer une injection de liquideou
d'autresblessuressbrieuses, unincendie,uneexplosion ou
Compatib[llt&,.himique des corps
Bl6ments ou accessoires utilisBs avec cet appareil..
d'autres dbgats.
NEJAMAISalt6rer ou modifier une piece de cet apparail; ceci Toujours lire soigneusement
1% documents et brochures du
fabricantdesfluides et solvantsutilis6savant des'enservir
risqueraitd'entrainer
son mauvaisfonctionnement.danscepulv4risateur.
VERIFIER regulibrementtout I'appareil de pulvdrisation
et'ses
Bquipements et r6parer ou remplacerimmediatament 185
MESURES DE SECURITECONCERNANT LES TUYAUX FLEXlBLES
pieces us& ou abimks.
Le fluide
B hautepressioncirculantdans Ies tuyauxpeut &e MANIPULERLES TUYAUX AVECPRECAUTIONET
trbsdangereux. Encasde fuite sur
le tuyau.defissure,CHOlSlRSOIGNEUSEMENTLEURCHEMIN.Nepasdeplacer
dBchirure ou rupture
B la suite de I'usure, da d@&s ou d'une
mauvaise utilisation,
les projections de fluide haute pression
le fluide en tirant sur le tuyau. Ne pas m'liser de fluides ou de
solvants qui ne sontpascompatibles avecI'enveioppe in-
qui
en proviennentpeuvententrainerdesblessuresgravespartbrieure ou extbieure du tuyau.NEPASexposer le tuyau B
penetrationsouslapeauouparcontact,ainsique desdBgetsdestemperaturessuphrieures B 82'CI1Bo"F) ou infbrieures B
met4riels.-40°CI-4O"FI. TOUS LES TUYAUX FLEXIBLES DOIVENT
AVOlR DES Continuit4de la mise A la terre des tUyaUX
RESSORTSSPIRALE DE PROTECTION AUX 2 BOUTS1
Les spirales deprotectioncontribuent
& Bviter la formation de Unebonnecontinuit6delamise
B laterredestuyaux est
hentiellepour maintenir la mise A la terre de I'ensemble de
pliures, de.bouclesou de noeuds sur18s tuyaux qui pourraient
entralner la rupture
du tuyeu B I'endroit du reccord ou B son vaporisation. VBrifiez
la resistance Blectrique de vos tuyaux B
voisinag.4. fluides et
B air, au moins una fois par ssrnaine.Sivotretuyeu
S~R~ER FERMEMEN~ leS raccords avant chaque UtiliSa. quemaximum.prenezcontactavec 10 fournisseurde waux
ne compone pas d'etiquene qui precise la resistance Blectri-
tion, Le fluide sous pression peut faire sauter un raccord ou lafabricantpouravoir tes limitesderesistancemaximum.
dessedouproduireunjet
B hautepressions'6chappantpar 10 vOtre tuyau et vBrifiez rBsinance, si ceIIe-ci depasse Ies
Utilisez un metre de resistance de la gamme appropribpour
raccord. limitesrecommandBas,remplacez
le tuyauimm6diatement.
utilisation,verifierentibrementchaquetuyaupour d4celer
les recte peutentrainer des risqus pourvotre systbme. Lisez
NE JAMAIS utiliser un tuyauendommag&AvantchaqueUntuyausansmise B laterreouavecunemise B laterreincor-
coupures,fuites,abrasions, bourwuflures deI'enveloppe ou aussiLESRISQUESD'INCENDIE OU D'EXPLOSIONci-
toute autre deteriorationoujeu des raccords. Si l'on constate
rune decesdbteriorations,
il taut remplacer le tuyau im- dessus.
m6diatement. NE PAS essayer de refaire la raccord
d'un tuyau
.haute pression
ni de reparer le tuyau avecduruban adhBsifou
oar tout autre moven. Un tuvau rBoar4
ne Deut Das resister au
fluide sous pression.
RISQUES D'INCENDIE OUD'EXPLOSION
Da I'BlectricitB statique est produite' par le passage du fluide B
grande vitesse dans la pompeetdans Ies tuyaux. Sitoutes Ies
pieces de I'appareil de pulv6risation ne sont pas convenable-
ment reliks
B la masse ou la terre, des Btincelles peuvent se
produire et I'appareilrisqued'btredangereux.DesBtincelles
peuvent egalement
se produire B l'occasion du branchement
ou
du debranchemant du cordon d'aiimentation. Les Btincelles
sontsuffisantespourallumer
185 vapeursdesolvants et le
fluide pulv6risB. Ies finespaniculesdepoussibreainsique
d'autressubstancesinflammables,quand on pulverise
I'in-
tBrieur ou B I'extdrieur, et elles peuventcauser un incendieou
una explosion, einsi que des blessures graves et des degats
trouvant
B au moins 6 m 120 pieds) de I'appareil et de I'endroit
mat6riels. Toujours branchar
le pulv4risateur dans une prise se
cordon d'alimentation que1 qu'il soit dans la zone ob se fait la
ob se fait la puiverisation. Ne pas brancherou debrancher un
pulv6risation quand
il y a le moindre risque que des vapeurs
encore presentes dans I'air prennent feu.
..
S'il se produit des Btincelles d'6lectricit6 statique, ou si vous
ressentez la moindre d6charge.ARRETU IMMEDIATEMENT
LA PULVERISATION. VBrifiez que le svstbme entier est bien
mis B la terre. Ne vous serw)z pai du sysieme avant qualapro-
blbme soit identifie et corrig4.
Mise A la term ou a la masse
Pour reduire 18s risques de production d'etincelles d'Blectricit6
statique,
le pulvhrisateur et tous Ies Bquipements utilisbsou se
tmuvant dans la zone de pulveisation doivent &re relib B la
terreou B la masse. Pour connaltre la detail des instructions de
mise
A laterredanslaregion et le type paniculier d'Bquipe-
ment. CONSULTER
le codeou les reglementationp Blectriques
locales. S'ASSURER que tous
les Bquipements de pulv6risa-
tionsuivents sont bien relies
B laterre:
1. Pulv.4risateur:Erancher le cordond'alimentation ou. la
rallongequidoivent &re Bquipkd'une prise
B 3 fiches enbon
&at,dansuneprisedecourantconvenablementmise
B la
terre. Ne pasutiliser d'adaptateur. Toutes
les railonges doivent
avoir
3 fils et Atre prbues pour 15 ampbres.
2. Tuyeux flexibles: Afin d'assurer la continuit6 de la mise B la
terre, n'utiliser que des tuyaux cornportant une mise B la terre
et ayantunelongueurmaximum combink de150 m
(15CO pieds).Sa reponer &dement auparagraphe"Con-
tlnult6
du circuit de mlse B la terra des tuysux".
3. Pistolet:RBaliser la'mise B laterreen le raccordant B un
tuyau flexibleet
B un pulvbrisateur deja convenablementrelib
B le terre.
4. Recipient d'alimentation: observer IB code ou Ies reelemen-
tations locales.
5. Objefs, matdriel ou surfaces recevant la pulvdrisation:
observer
le code ou Ies r@lementations locales.
6. Tous les seaux de solvants utili& pour le rincage: observer
le codeou Ies reglementations locales.Nutiliserque des seaux
mdtalliques conducteurs de I'6lectricite. Ne pas mettre leseau
sur unesuriaace non conductrice
comme sur du papierou du
7. hur conserver /a continuitd
de la mise
d kt tern
quand on
canon car cela interromprait la
continuit6
le la mise B la terre.
rinca le matdriel
ou wend on libdm la pression,toujours
maintenir une panie mbtalliquedupistolet fermementappuyb
contre
le c6t6d'un seau en mdtalpuis appuyer sur la detente
du pistolet.
Mesures de SBeuritB concernant le Rincege
Pourreduire 185 risquesdeblessuresparp(ln4trationde la
peau et les risquesdiis aux Btincelles d'6lectncltB statique ou
aux Bclaboussures, observer
la rnarche B suiwe pour le rincage
donnk
B la page 12de cemanuel. Observer la "Merche B
Suivrs pour DBtendre la Pression" donnee B la page 4 en
enlever lsjutage
du pulvdrisateur evantlerincage. Maintenir
une panie metallique du pistolet fermement appuy6e contre
le
cbt6 d'un seau en m&al et utitiserlapression la plusfaible
possible pendent
le rincage.
307-758 5

EL ROCIADO A ALTA PRESION PUEDE CAUSAR GRAVES LESIONES.
SOLO PARA US0 PROFESIONAL.RESPETELOS AVISOS DE ADVERTENCIA.
Lea
y entienda todo el manual de instrucciones antes de manejar el equipo.
PELIGRO DE INYECCION DE FLUID0
Seguridad general
Este equipogenera un fluido aunapresi6n muy aka.
El
rociadodelapistola, 10s escapesde fluido o roturasde 10s
componentes pueden inyectar fluido en le piel y e1 cuerpo y
Causar lesiones enrernadamentegraves, incluyendo a veces la
salpicado en
10s ojos puede causar graves daKos.
necesidaddeamputaci6n.Tambibn,
e1 fluido inyectado o
cuerpo. NUNCA colocar la mano o 10s dedos encima de la bo-
NUNCAapuntarlapistolahaciaalguien
o algunapanedel
quilla. NUNCA tretar de "hacer retornar
la pintura"; este NO
es un sisterna de rociado de aire.
pistola mientras
se est6 pulverizando.
SIEMPRE tenercolocado
e1 protectordelaboquillaenla
dado
m6s abjo, antes de lirnpiar o sacarla boquilla o dedar
SIEMPRE seguir
el procedimiento dedescargadepresibn,
servicio a cualiquier equipo del sistema.
NUNCA tratar de parar
o desviar 10s escapescon la mano o el
cuerpo.
estBn funcionando bien antes de cada uso.
hurarquetodos
10s aparatosdeseguridaddelequipo
Tratamienta
medica
Aviso al medico: Sise llega a inyectareste fluido en lapiel
se
causa unalesidntraumdtica. Es imponanretratar
qulrhgicamante
la lesi6n a le brevedadposible. No
demorar el tratamiento para investigar la toxicidad. La tox-
icidadesalgode sum8 importanciaenelgunaspinturas
exdticascuandoseinyactandirectamente
al torrente
sanguineo.Sir4convenienteconsultar
a unespeciaiistaen
citugia pldstica
o reconstructive de las menos.
Asqurar quetodos 10s aparatosprotectoresdelapistole
Aparatos de seguridad de la pistola pulverizadora
esthnfuncionandobienantesdecadauso.Nosacar
ni
malfuncionamiento de la misma conIasconsiguientes lesiones
rnodificarningunapiezadelapistolepuespodriacausar
e1
penonales.
Pestillo de seguridad
Cadavez que se deje de pulverizar, aunquesea por un breve
momento,siemprecolocar
e1 pestillodeseguridad enla
posici6n"cerrada",
lo quedejalapistolainoperante. El no
hacerlo puede llevar al disparo imprevisto de la pistole.
Difusor
e1 riesgo deinyecci6ncuando no est4 instaiadalaboquilla.
El difusor de la pistola dispersa e1 chorro pulverizado y reduce
Revisar con regularidad
el funcionamiento del difusor. Seguir
y despu6ssacarlaboquilla.Apuntarlapistola a unbalde
el procedimiento dedescarga depresi6n. dado rnhs abajo,
methlico,sosteniendolabienfirmecontra
81. Utilizandola
presi6n
m4s bajoposible,dispararlapistola.Si el fluido
emitido
no sale disperso en un chorro irregular, reernplazar de
inmediato
e1 difusor.
Rotector de 10 boquilla
SIEMPREtener el protectordelaboquillacolocadoenla
pistola mientras
se est6 pulverizando. kteprotector llama la
atenci6n contra el peligro de inyeccidn
y ayuda a reducir, per0
noevita, la colocaci6n accidental de
10s dedos o cualquierotra
pane del cuerpocerca de la boquilla.
Seguridad
de la boquilla pulverizadora
Tenermuchocuidadoallirnpiar
o cambiarIasboquillas.Si
pestillo delapistoiadeinmedieto.SIEMPREseguir
e1 pro-
llegare a obstruirse mientras esth pulverizando, enganchar e1
cadimianto dedescargadepresi6n y despu6s sacar la bo-
quilla para limpjarla.
quiilaantesdeque
se hayadescargadoporcompletola
NUNCA limpia8la acumulaci6n de pinture alrededor de labo-
presi6n
y e1 pestillo est6 enganchado.
.. . .
Marche B Suivre pour DBtendre la Pression
Pourreduire Ies risquesdeblessuresgraves, y compris Ies blessuresparinjectiondefluide ou ceilescaus.&pardes
Bclaboussures dans
18s yeuxousur la peau, des pieces en mouvernentoupar Blectrocution, toujours bien observer cene marche
8 suivre B chaque fois que I'on arrete le pulv6risateur. B l'occasion de la verificationou de la reparation d'une piece de I'appareil
de pulvbrisation,
B I'occasion de I'installgtion,du nettoyageou du remplacement des ajutages et d'une maniere gBn6rale B cha-
queerr&. 11 Engager le verrou de sBcurit6du pistolet. 21 MettreI'interrupteur Marche-ArrBt sur ARRET I"OFF"1. 31 Debrancher
ferrnementappuyhcontre
le c8t6d'un seau en metal, appuyer sur la gachene du pistolet pour liberer la pression. 6) Engager le
le cordon d'alimentation. 4) Ddsengager le verrou de skurite du pistolet. 5) En maintenant une panie metalliquedu pistolet
81 hisser la soupape ouvenejusqu'i ce que !e pulvbrisateur soit de nouveau pr& B &re utili&.
verrou de sbcuritbdu pistolet. 7) Ouvrir la soupape de sBcurite en prenant soin d'avoir un recipientprbt B rBcup4rer le liquide.
Sil'on soupconne que /'aiutage dupulvdrisateur ou le tuvau est compldtement bouchd. ou quela pression n'epas dtd compldte
ment libdrde aprhs awirprocddd
aux op6rations ci-dessus. desserrer TRES LENTEMENTI'krou de retenue de la protection de
I'ajutage ou
le raccorddu bout dutuyau et libher progressivement la pression, puis terminer le desserrage. Onpeut maintenant
dbbouchec I'a'uta
e ou le tuyau.
1 2 3 7
6 307-758

PELIGRO POR MAL US0 DEL EQUIP0
Cualquier mal us0 dd equipo pulverizador o 10s accesorios, tal
Segurided general
wmo sobrepresurizaci6n.modificaci6ndepiezhs, us0 de
materiales
y produnoe quimicosincompatibles, o utilizaci6n
de piezas dafladas
o desgastadas, puede hacen que se rompan
y causen lainyecci6nde fluido u otraslesionescorporales ,
graves, incendio, explosi6n o daRonala propiedad.
NUNCA alterar
o modificar ninguna pieza de este equipo; e1
hacerlo podrla causar una averla.
REVISAR con regularidad
e1 equipo pulverizador y reparar o
reemplazar de inmediato Ias piezas dafladas o desgastadas.
Esta pulvarizadora puede desarrollar 1% barias (2750 psi1 de
Presi6ndel sistema
PRESION DE TRABAJO MAXIMA. Asegurarquetodo e1
equipo pulverizador y sus accesorios tienen la capacidad para
aguantar la presidn
maxima de trabajo de esta pulverizadora.
NOexcederla presi6nmaximadetrabajodeningdncom-
ponente
o accesorio de este sistema.
solventeantes de usarlos en esta pulverizadora.
Siempre leer 18s instrucciones delfabricantedel fluido
y
SEGURIDAD EN EL US0 DE LAS MANGUERAS
Ei fluido que escapa a aka presi6n por 18s mangueras puede
ser
muy peligroso. Sien la manguera se desarrolla un escape,
unarotura
o rajaduradebidoacualquier tip0 dedesgaste,
daflo
o maltrato. e1 chorro a aka oresi6n emitido oorall1 ouede
.~ ~~ ~
&marunalesibn por inyeccidn u otraslesionescorporales
graves
o daflos a la propiedad.
.~
QUE TENER GUARDAS DE RESORTE EN AMBOS EX-
lTODAS
US MANGUERAS PARA FLUIDOS TIENEN
TREMOSl Estas protegenIasmanguerascontradobleces
o
retorceduras en 10s acoplamientos o cercade ellos. 10s que
podrlan traducirseen roturas de la manguera.
Antes de usarlas, APRETAR bien firmes todas18s conexiones.
Ei Ruido a alta presi6n puede desalojar un acoplamiento suelto
o dejar que por 41 escape un chorro a aka presi6n.
NUNCAusarunamanguera
que est6daRada.Siempre,
abultada,
0 acoplamientos sueltos o daflados. Si llegara a en-
revisarla en busca de cortaduras, escapes, abrasi6n. cubierta
contrarse cualquiera de estas condiciones, reemplazar de
in-
mediato la manguera. NO intentar reacoplar una manguera de
similar. Una menguera que ha sido remendada no aguante
e1
aka presi6n o enmendarlacon cinta adhesive u otro material
Ruido a alta presibn.
MANEJAR
Y PASARCUIDADOSAMENTELAS
MANGUERAS.
No tirarde 18s manguerasparamover e1
eauipo. No usBr fluidos o solventesaue Sean incomoatibles
con
el tubo interno y la cubierta dela manguera. NO exponer
las manguerasatemperatures sobre 82°C 1180°F) o bajo
-4OT I-40°F).
Contlnuidaddelcircuitodepuesta a tierra de la
manguera
esencialparamantenerconectadoatierra e1 sistema
La continuidaddel circuito depuestaatierraapropiado es
pulverizador. Es indispensablerevisarlaresistenciael4ctrica
maxima de
las mangueras de aire y defluidopor lo menos una
vez alasemana. Si la manguera notiene una etiqueta enla
cual
se especifica la resistenciaelktrica maxima, ponerse en
confanocon
e1 proveedor o fabricante de le manguera para la
informaci6n sobre 10s limites de resistencia. Usar un metro de
resistencia
en la gama apropiade Dara cornprobar la resisten-
PELIGRO DE INCENDIO 0 EXPLOSION
mangueracreaelectricldadsstAtica. Si todas les partes dal
Ei flujo aaltavelocidaddel fluido a1 pasarpor labomba y
equip0pulverizador no tienenbuenatierra,puedenocurrir
chispas. convirtiendo al sistema en algo peligroso. Tambibn,
pueden producirse chispas al enchufar
o desenchufar el cor-
d6nel6ctrico. Estaschispaspuedeninflamar
10s vaporesde
10s solventes y el chorro de fluido pulverizado, particulas de
polvo
y otrassustanciasinflamables.seaalairelibre o baio
techo,
Io que podriacausar una explosi6n o incendio y graves
lesiones corporales
y daflos a la propiedad. Enchufar siempre
la pulverizadora
a un tomacorriente que se encuentre a por lo
menos 6 m (20 pies)de la m4quina y del area que se vaa
e1 lugardonde se est&rociandocuandotodaviaexista la
rociar. No enchufar o desenchufar ningdn cordbn electric0 en
posibilidad de
que queden vapores inflamables en el aire.
choque'el4ctrico
mientras se us8 el equipo, DWAR DE
Si ocurre una chispa de electricidad esthtica o incluso un ligero
buscadeuna tierraapropiada. No usardenuevo
el sistema
PULVERIZARDEINMEDIATO.Revisar todo
e1 sistemaen
hasta haber identificado
y solucionado e1 problema.
Puesta a tierra
Para reducir el riesgo de chispas estdticas, conectar a tierra la
se encuentre en el lugar que se va a rociar. CONSULTAR el
pulverizadora y todo el otro equipo de pulverizar que se use o
c6digo elbctrico de la localidad para las instrucciones sobre las
conexionesatierraexigidasparalazona
y tipo deequipo.
ASEGURARde conectaratierra todo esteequipo
pulverizador:
1. Pulverizadora: enchufar el cordbn el4ctrico. o cable exten-
sor, cada uno con
un enchuf de tres patas en buen estado, a
untomacorrienteconpuestaatierraapropiado.No usar un
adaptador. Totos
10s cables extensores tienen que tener tres
hilos y una capacidad de 15 amperios.
2. Mangoerasparafluidos:usarsolamentemanguerascon
puestaatierradeuna longitud combinadade
150 m
tambih alpdrrafosobre continuidad a tlerrade la
1500 pies), para asegurar buena continuidad a tierra. Referirse
manguera.
3. pistola:hacerlapuestaa tierraconecthndolaauna
manguera defluido
y pulverizadorabienconectadas a tierra.
4. Suministrar un recf'piente:deacuerdoal c6digodela
localidad.
5. Objeto qua se estd rociando: de conformidad con e1 c6digo
local.
6. Todos 10s baldes de solvente usados durante el lavado, de
conformidadcon
el c6digolocal.Usarsolamentebaldesde
metal,que
Sean conductivos.Nocolocareibalde enuna
superficie no conductiva,comopapel
o cart6n.queinter-
rumpe
la continuidad a tierra.
7. Para mantener la continuidad a tierra durante el lavado o
descarga de presidn, siempre apoyar una parte metalica dela
pistolabienfirmecontra
el costadodel balde de metal,
despu6s apretar el gatillo.
Seguridad durante el lavado
Para reducir el riesgo de que se inyecte o salpiquefluido en la
piel,
o que ocurra una descarga de electricidad estBtica. siem-
preseguir las INSTRUCCIONES PARA EL LAVADO, dadas
en
lapagina12.Seguir el procedlmlentode descergade
presl6n en la phgna 6, y quitar la boquiila rociadora antes de
Iavar. Apoyar una parte methlica de la pistola bien firrne contra
el costadode un balde de metal y usar ie presi6n mas baja
posible de fluid0 durante
e1 lavado.
cia;siexcede
10s limites recomendados, rwmplazarla de in-
mediato. Es muyarriesgadotenerunamanguerasinpuestaa PELIGRO DE LASPlEZASMOVILES
tierra 0 con la puesta a tierraen malas condiciones. Leer tam-
bi4nlainformaci6nsobreRIESGO DEINCENDIO 0 EXPLO-otraspanesdelcuerpo.MANTENERSEALEJADOdeIas
as piezas en movimiento pueden pinchar o amputar dedos u
SION. mds arriba.piezasenmovimientodurante e1 arranque 0 funcionamiento
de la pulverizadora. Desenchufar la pulverizadora
y descargar
la presi6n antes
de revisar o dar servicio, a cualquier parte de
pulverizadora, para irnpedir que arranque inesperadamente.
IMPORTANT
Se han adoptadolas normas de seguridad del gobierno de 10s
Estados Unidos de Norteambrica bajo e1 Acta de Seguridad y
SaludOcupacional.DeberAnconsultarseestasnormas.en
especial las Generales, Parte
1910, y las Normas de Construe-
cibn, Parte 1926.
*"-I 7=0 7
~~~

INTRODUCTION
Model 231441 ahown
ULTRAm
WO BAS1
PRESSURE CONTROL KNOB
ELECTRIC MOTOR
CIRCUIT BREAKER
RESET BUTTON
DRIVEASSEMBLY
PAILHANQER
ONIOFFSWITCH
PRESSURE RELIEFVALVE
MAIN FLUID HOSE
WHIP HOSE
Your new UltraTM 500 Sprayer functions and operates
differentlythan other airless paint sprayers. This section
will help you become familiar with the sprayer before
operating
it.
Thepressurecontrolincludes an ON/OFF switchforthe
Pressure Control
sprayer, the pressureadjustingcontrolknob, apressure
sensingdevice,and a current overload circuit breaker
withamanual resetbunon.
Its functionistocontrolthe
motor
speed so that the sprayer maintainsconstant
fluid pressure
at the pump outlet.
Motor
The DC motor hassealedbearingsandreplaceable
motor brushes.
Its function istodrivethe displacement
pump et the rate needed to supplysufficientpaint
volumestthe selected pressure.
Workingtogether, the pressure control and motor
cause the pump to cyclewheneverthereis fluid or
pressure demand. Whenthe pump is cycling, themotor
sounds like an automobile starter cranking. When the
pump is not cycling,themotor hums,hums intermit-
tently, orappears
to have shut 'tself off. However, there
will still be power to the sprayerand it will stay
off and relieve pressure.
pressurized and readytouse unless you manuallyshut
it
Because the motor is DC, it is less sensitive to low
voltage or voltage fluctuations thanan ACmotor, and a
heavy gsuge.extension cordof up to
150 feet 145 m)
can be used.
The sealed drive assembly transfers powerfrom the DC
Drive Assembly
motortothe displacement pump.
Displacement Pump
The positivedisplacement, volume-balancedpumppro-
vides
equal fluid deliveryon both the upand down
filled
with Graco Throat Seal Liquid,helpsprevent
pump strokes. The pump has e wet-cup which, when
damage tothe throatpackings andpistonrod.
Ruld Fllter
The fluid filter providesthe final paint strainingto help
avoid c!qs in the hose and spray tip. Thefilter,includes
a reusable element anda pressure relief valvefor reliev-
ingfluid pressure whenshutting
off the sprayer.
The grounded, nylonspray hoses havespringguardson
Hoses
bothends. The
50 foot (15.2 m)hose has a 1/4 in. ID.
The 3 foot (0.9 m), 3/16 in. ID whip hoseallows flexi-
ble gun movement. The nylon hose material ects as a
pulsation dampenerto absorb pressurefluctuations.
Spray Gun
8 Reverse-A-Clean 111 Spray Tip
whichprevents accidental triggering when
it isengaged
Gracohighpressurespraygunshave
s trigger safety
(see below).The Reverse-A-Clean 111 spraytipuses high
pressure fluid to removeclogs from the spraytup
without removing
it fromthegun. It includes a safetytip
guardwhich helps reducethe risk of injection injury.

1. Connect Hose and Gun (Rafer to Fig 1.1
a. Remove theplasticcapplug from the filter
fluid hose onto the nipple.
outlet nipple and screw the
50 ft (15.2 mlmain
b. Connect the whip hose betweenthe fluid hose
and the gun inlet connection.
c.Don't
usa threadsealant,anddon't installthe
spray tip yatl
WARNING
If you are supplying your own hosesandspray
gun,besura they areelectricallygroundedand
ratad for at least
2750 psi 1195 bar) Working
Ressure,
and that the gunhas a tipguard. Thisis
to reduce the risk of serious bodily injury caused
bystaticsparking and fluid injection orover-
pressurizing end rupturing theequipment.
-
TCAUT'ON1
To avoiddamagingthepressurecontrol, which
may result in poor equipmentperformanceand
component damage, follow these precautions:
1. Always usa nylon sprayhose of at least
50 ft (15.2 m)long.
2. Never use a wirebraidhose as it is too rigid
3. Never install any shutoff devicebetween
to act
as a pulsation dampener.
4. Always usa the main filter outlet for one-
the filter and the main hose.
See Fig 2.
gun operation. Never plug this outlet.
I I
2. Fill PackingNutlWet-Cup (See Fig 2.)
Throat Seal Liquid (TSL), supplied.
Fillthepacking nut/wet-cup
113 fullwith Graco
3. CheckElectrical Service
a. Be sure theelectricalservice is 120 V,
60 HzAC, 15 Amp(minimum) and that the
outlet
you use is properly grounded.
b.
Use anextensioncord which has 3 wires of a
minimum 12 gauge size, and a maximum of
150 ft 145 m) long. Longer lengthsmay affect
sprayer performance.
a.
b.
c.
4. Plug In the Sprayer
Be sure the ON/OFF switch is OFF.Refer to
Fig 3.
Plug thepowersupplycord into a grounded
from tha spray area to reduce the chance of
a
electricaloutletthat isat least 20 R (6 m) away
spark ignitingthe spray vapors.
supplycordplug, which is the grounding
Do not remove the third prong of the power
prong, and do not
usa an adapter.
5. Flush thepumpto remove the lightweight oil
which was
left in to protect pump parts after fac-
tory testing.
a. Before using water-base paint, flush with
then
s clean water flush.
mineralspirits followed by soapywater,and
b. Beforeusingoil-base paint, flush with mineral
spiritsonly.
ANY SHUTOFF
m 3
c. See FLUSHINGGUIDELINESon page 12 for
flushing procedure.
6. Preparethe paintaccordingtothe manufacturer's
recommendations.
a. Removeanyskin that mayhaveformed.
b. Stir thepaint to dissolvepigments.
c. Strain the paint through
a fine nylonmesh bag
(availableat most paint dealers) toremove par-
is probably the most important step toward
tidesthat couldclog thefilter or spraytip. This
trouble-free spray painting.
307-758 9

Pressure Relief Procedure
WARNING
To reduce the risk of serious bodilyinjury, in-
cludingfluid injectionor splashing
in theeyes oron
theskin, or injury from movingparts or electric
shock, alwaysfollow this procedure whenever you
shut
off the sprayer, when checking or servicing
any pert of the spraysystem,wheninstalling,
cleaning or changing spray
tips, and wheneveryou
stop spraying.
2. Turn the ONlOFFswitch to OFF.
1.Engage the gun safety latch.
3. Unplug the power supply cord.
4. Disengage the gun safety latch.
5. Hold e metalpartof the gunfirmlytotheside of
a metalpail,andtriggerthegun to relieve
pressure.
8. Engage the gun safety latch.
7:Open the pressurereliefvalve,having
e con-
8. Leave the pressurereliefvalveopen until you
tainer readyto catchthe drainage.
ere reedy to operate the sprayer again.
plate& clogged,
or that
pressure has notbeenfully
If
you suspect that the spraytip
or hose is com-
relieved after followingthestepsabove, VERY
SLOWLYloosen the tip guardretaining nut or
hose end coupling and relieve pressure gradually.
Then loosen thenut completely. Now clear thetip
or hose obstruction.
1. Primethe Sprayer
with Paint.
a. Close thefilter's pressure relief valve. See Fig 1.
b. Don'tinstallthe spray tip yet1
c. Put the suction tube intothe paint container.
d. Turn the pressureadjustingknob
all the way
counterclockwisetolower the pressure setting.
e. Disengagethe gunsafetylatch.
f. Hold a metalpart of the gunfirmly against end
aimedinto
a metal waste container. See Fig 4.
ONIOFFswitchtoON, and slowly increase the
Squeeze the trigger and hold
it open, turn the
pressure setting until the sprayer
starts. This
procedurereducestheriskofstaticelectric
dischargeandsplashing.Keepthe gun trig-
gered until
all air is forcedout of the system and
thepaintflowsfreelyfromthe gun. Releasethe
trigger and engagethe safety.
NOTE: If the pump isherd to prime, place a con-
tainer under the pressure relief valve and
open
it. When fluidcomesfromthevalve,
close
it. Thendisengage thegunsafety
latch andproceed
as in Step If, above.
g. Check
ell fluid connectionsfor leeks. If any are
found, follow the Pressure Relief Procedure
Warnlng, above, then tighten connections.
2. Instail the Spray Tip and Tip Guard
a. Besure the gun safetylatch is engaged.
(Refer to Fig
6.)
b. Unscrew the tip guardretaining nutfrom the
gun.
Fig
4
BE SURE GUN SAFETY LATCH
IS ENGAGE01
Fig 5
c. Installthe Reverse-A-CleanTM 111 sprayhousing
withtip installed.See the RAC
111 packaging
labelfor instructions.
d. Tighten the retainingnut byhand untilsnug.
e. Use a wrenchtotightenthe retainingnutabout
118to 1/6turn.
Overtightening the retainingnut
will damage the
CAUTION
seat gasket end resultin leakage.
3. Adjustingthe Spray Pattern
a. Increase the pressureadjusting knob setting
just until spray fromthe gun is completely
atomized. To avoidexcessive ovenpray and
the life of the sprayer,alwaysuse the lowest
fogging, and
to decrease tip wear and extend
possiblepressureneeded
to get the desired
results.
b.
If morecoverageisneeded,use e larger tip
rather than increasing the pressure.
c. Test the spraypenern. To adjust the direction
of the spraypattern,engage the gun safety
latch endloosen the retainingnut. Position the
tip
so the groove is horizontalfor e horizontal
pattern or vertical for e vertical pattern. Then
tighten the retaining nut.

4.
5.
Operatlng Tips. These suggestionswill help pre-
vent the motor from runningtoo hot or operating
intermittently.
a. Decreasethe pressurewhen using a small tip.
b. Keep the sprayer in
e shaded area when spray-
ing outdoors.
c.Turn
off the sprayerandrelievepressure
whenever vou stoo soravina.
-ARNING
To reduce the risk of serious bodily injury from
fluid injection orsplashing in the.eyesor on the
skin,useextreme cautionwhen cleaningor
changingspraytips. If the spray tip clogs while
spraying, engage the gunsafety latchimmediate-
ly, then follow theprocedure in Steps
%-5e,
below.
Cleaning
e Clogged Tip
I
NEVER wipe off buildup aroundthespraytip until
pressureisfully relieved andthegun safety latchis
engaged.
a. Clean the front of the tip frequently during the
day's operation. First, follow the Pressure
use
a solvent-soaked brushto keep paint from
Relief Procedure Warningon page
10. Then
building up and clogging the tip.
spray tip handle
180°. See Fig 6.
ger,engage thegunsafety,and rotate the
c. Disengage the gun safety latch and trigger
the
gun into a waste container. Engage thegun
safety latch again.
b. If the spray tip doesclog,release the gun trig
d. Returnthehandle to theoriginalposition,
disengage thegunsafety,andresumespray-
ing.
8. If the tip is still clogged, engage the gun safety
latch, shut off end unplug the sprayer, and
open the pressurereliefvalve to relieve
pressure. Clem the spray tip.
1.
2.
3.
SHUTDOWN AND CARE
Check thepackingnut/wet-cup dally. First
follow the Pressure Rellef ProcedureWarning
at
all times to helppreventpaintbuilduponthe
on page
10. Be sure the wet-cup is 1/3 full of TSL
piston rod andprematurewear of packings. The
pecking nut shouldbe tight enough to stop
leakage, but notighter. Overtightening may cause
bindinaand excessive Dackina weer.
Use a screw-
driverand light hammer to idjust thenut.
See
Fig 7.
sprayer is stored. First follow the Pressure Relief
Clean thefluidfllteroften andwheneverthe
Procedure Warningon page
10. Refer to manual
307-273, supplied, for the cleaning procedure.
and
fill it with mineral spiritsto help prevent pump
Flush the sprayer at theend
of each work day
corrosion end freezing. See "FlushingGuidelines"
on page
12.
CAUTION
Never leave water or any paintinthesprayer over-
night to:
(1) preventpumpcorrosion; (2) to pre-
vent the paint or waterfrom freezing
in the pump
andpressure control which cancause
loss of
Always use mineralspirits for thefinalflush.
pressure, stalling orserioussprayerdamage.
Relieve pressure. This leaves
a protective coating
of mineral spiritsinthe sprayer.
4. For very short shutoffperiods, leavethe suction
tube in the paint, follow the Pressure Rellef Pro-
cedure Warningon page
10, and clean the spray
tip.
5. Coil the hose andhang it on the hoserackwhen
storing
it, even for overnight, to help protect the
hose fromkinking, abrasion, couplingdamage, etc.
Fl9
7
Wt7.7M 11

FLUSHING GUIDELINES
When to Flush
5. Storage.
1. New Sprayer. YournewUltraTM 500 Sprayerwas
factorytestedin lightweightoil whichwas
left in to
Water-base pelnt flush with water, then mineral
spiritsand leavethe pump, hose and gunfilledwith
Before
using water-base pelnt, flushwith mineral
protectpumpparts.mineralspirits.Shut
off andunplugthesprayer,
spirits. followed by soapy weter, and then
e clean open the pressurereliefvalve to relievepressure
and
leave open.
water
flush.^ Oll-basepalnt: flush with mineralspirits.Shut off
Before uslng oil-basepalnt, flush with mineralandunplugthe sprayer,open the pressurerelief
spiritsonly. valve to relievepressureandleaveopen.
such
as mineral spiritsorwater.
Flush with soapy water, than mineral spirits.
then
a clean water flush.
Flushwith mineralspirits, followedbysoapywater,isready to use.
2. ChangingColors. Flushwith a compatible solvent
6. Startupafter storage.
Before
uslng water-basepalnt, flush out mineral
3. Changing from water-base to oil-base paint. spirits with soapywaterand then
a cleanwater
flush.
When.uslng off-base paint, flush out the mineral
4. Changing from oil-base to water-base paint. spiriiwith thepaint to besprayedand the sprayer
How to Flush
1. Follow the Pre.esure Relief ProcedureWarning
on page
2 or 10.
2. Remove the filter bowl andscreen; see manual
307-273 supplied.Clean the screenseparatelyand
installthe bowl without the screen to flush
it. See
Fig 8.
3. Close the filter pressurereliefvalve.
4. Pour one-half gallon (2 liters)of compatible solvent
into
a bare metal pail. Put the suction tube inthe
pail.
5. Remove the spray tipfrom the gun.
WARNING
splashing, always remove the spray tip from the
gun, and hold
a metalpartof the gunfirmlytothe
side of and aimedinto
a grounded metel pail when
flushing.
8. Disengagethegunsafety latch. Point the spray gun
of the gun firmly touchingthemetalcontainer,
into
e metal wasta container and with e metal pert
squeeze the gun trigger.
Sea Fig 9. Thls pre
andsplashlng. With the gun triggered, turn the
cedure helps reduce the rlsk of statlc sparklng
ON/OFFswitchtoON andslowlyturnthe pressure
adjusting knob clockwise
lust untll the sprayer
starts. Keep the guntriggered until cleansolvent
comes from the nozzle.
Release the trigger and
engage the gun safety latch.
12 307-753
METALTO METAL
MAINTAIN FIRM
GUN AND CONTAINER
CONTACT BETWEEN
Fig 9
7. Check all fluid connections for leaks. If any leak,
first follow the Pressure Relief Procedure Warn-
start the sprayer, and recheck the connections for
ingon page
2 or 10. Now tightenthe connections,
leaks.
8. Remove thesuctiontube from thepail.Disengage
the gun
safety and triggerthe gun toforce dvant
from the hose.
Do, not let the pump run dry for
morethan 30 seconds towold damaglngthe
pump packlngsf
Then turn ON/OFFswitchtoOFF
and engagethe gun safety.
9. Unplugthepowersupplycord. Open the pressure
the sprayeragain.Unscrew the filter bowl and
relief valve and leave openuntilyouare readyto
use
reinstall the clean screen. Reinstall the bowl, hand
tight only.
10. If you have flushedwith mineral spiritsend are go-
water followedby
a clean water flush. Then repeat
ing to
use e water-basepaint, flush with soapy
Step
1.

TROUBLESHOOTINGGUIDE
Pressure
Relief Procedure
WARNING
To reducethe risk of serious bodily injury, including fluid injection, splashing fluid in the eyes or on theskin, or in-
jury from moving parts or electric shock, always follow this procedure whenever you shut off the sprayer, when
checking or servicing any part
of the spray system,when installing, cleaning or changing spray tips, and whenever
you stop spraying.
2. Turn the ONlOFF switch to OFF.
1. Engage thegun safety latch.
3. Unplug the powersupplycord.
4. Disengage the gun safety latch.
5. Hold a metal part of the gun firmly to theside of a metal pail, and trigger the gun to relievepressure.
6. Engage the gun safety latch.
7. Open the pressurerelief valva.
8. Leave the pressure relief valve open until you are ready to spray again.
If you suspect that the spray tip or hose is completely clogged, or thatpressure has not been fully relievedafter
following the steps
above, VERY SLOWLY loosen the tip guard retaining nut or hose end coupling and relieve
pressure gradually, then loosen completely.
Now clear the tip orhose.
PE OF PROBLEM
ITOR WON'T OPERATE
iic FluidPressureProblems
;icMechanicalProblems
iicElectrical Problems
WHAT TO CHECK
Ifcheck Is OK, go to next check I When check la not OK refer to thls cdum~
WHAT TO DO
1. Checkthepressure control knob setting. The
1. Slowly increase the pressure setting to see ii
motor will not run if it is at the minimum set-
ting (fullycounterclockwise). the motor starts.
2. Checkfor a clogged spraytip. Refer to your or tip instruction manualfor tipcleaning. separate gun ortip instructionmanual. 2. Relivepressure, refer to your separate gun
1. Check for frozen or hardened paint inthe
tube. Using
a screwdriver, carefully try to
1. Thaw'. Plug in sprayerand turn on. Slowly
page
19.
starts. If it doesn't. replace the displacemeni
increase pressure setting to see
if motor
pump
(39) andlor pressure control bourdon
rotate fan
at back of motor by hand. See pump packings
(see manual 307-7931 andlor
replace the bare pressurecontrol box
(301)'.
sea page 26.
2. Check displacement pump connecting rod
2. Push pin into place and secure with the
pin
(20). It must be completely pushed into
connecting rod
(3) and spring retainer (35)
spring retainer.
should befirmly in groove of connecting rod.
see page 28.
3. Check for motor damage.Remove drive
2. Replace motor (1) if fan won't turn.
housing assembly
(2). See page 29. Try to
rotate fan by hand.
be sure
it has not popped up. circuit breaker continuesto open, see "Elec.
1. Checksprayer circuit breaker (309) button to
1. Depress circuit breaker button to reset. If
trical Short", page 16.
2. Check electrical supplywith volt meter.
Meter should read
105 to 125 VAC.
3. Check extension cord for visibledamage.
cord outlet to check.
Use a volt meter or teat lamp at extension
4. Check sprayer power supply cord (311) for
visible damage such as broken insulationor
wires.
5. Check motor brush leads, terminals and
brush length. Brush length should be
112"
minimum. See Dane 22.
2. Reset building circuit breaker:replace
buildingfuse. Try another electrical outlet.
3. Replaceextensioncord.
4. Replace power supply cord. See page 23.
5. lighten terminalscrews; replacebrushes.
See page
22.
'Thawthesprayer if waterorwater-basedpainthasfrozen in When replacing the barepressure controlbox(item 301).
it, due to exposure to low temperatures, by placing it in a
warm area. Do not tryto startthe sprayer until it has thawed remove the circuit breaker,ONlOFFswitch,bridge, circuit board and electrical hardware and reinstall these parts in the
freezing, the pump should operate.
If paint hardened(dried)in
Mmpletely.If the bourdontube was not damaged by the barebox.
the sprayer, the pump packingsandlor bare prossurecontrol
must be replaced.
See page 26 or manual 307-793.
Troubleshooting continuedon nextpage.
307-758 13

fPE OF PROBLEM
OTOR WONTOPERATE
gnosing circuit board in-
ator lamps. The normal
ndition is red lamp on,
1ar lamp on when board is
ring pump to run.
~llowPressureReliefPro-
dure. Remove gun from
lee. Remove pressure con-
)I cover and check for faulty
nps.
ndition
of circuit board
mdition A bothlamps
on:
Imp won't operate and
>toris not running
ondkion
B
0th lamps off
WHAT TO CHECK
It check Is OK, to tonext check
. Check leads from bridae (3081 to motor to be
sure thei are securelyiastened and properly
mated.
:. CheckG1andG2 connections betweencir-
cuit board
123) and bridge WS) for damage
or
10088 terminals.
,, Check for loose motor brush lead connec-
tions and terminals. See page
22.
.. Check brushlengthwhich should be 1/2"
minimum. Seepage 22.
the same rate on bothsides of the motor.
NOTE also that the brushes do not wear
at
i. Checkfor broken or misaligned motor brush
springs. Rolled portion of spring must rest
squarely
on top of brush. See page 22.
i. Check motor brushesfor binding in brush
holders. See page
22.
1. Check motor armature commutator for burn
spots, gouges and extreme roughness.
Remove motor coverand brush inspection
plates to check.
See page 22.
mature tester (growler) or perform spin test.
See page 19.
good bridgeor performlng brldge
teat. See
page 20.
CAUTION: Do not performthis check until
armature is determinedto be good. A bad
armaturewill immediately burn out
a good
bridge.
I. Check motor armaturefor shorts using ar-
j. Check bridge (308) by sybstitutingwith a
2. Check sprayer power supply cord (3111.
DisconnectTP6 femaleand TP1femaleand
sprayer. Meter should read 105 to 125 VAC.
connem volt meter to these leads. Plug in
Unplug sprayer. Reconnect TP1.
3. Check ONlOFF switch (303). DisconnectTP:
and connectvolt meter
to TPB female and
TP2 male. Plug
in sprayer and turn on. Mete
should read 105 to 125 VAC. Turn
off and
unplug sprayer. Reconnect TP2.
I. Check jumper wire (5%). DisconnectTP3
and
connect volt meter to TP6 female and
TP3 female. Plug insprayer and turn on.
Meter should read 105 to 125 VAC. Turn off
and unplug sprayer. Reconnect TP3.
5.Check circuit
breaker 1309). Connect volt
meter to TP6 female and TP4. Plug in
sprayer and turn
on. Meter should reed 105
to 125 VAC. Turn
off and unplug sprayer.
77
-
1.
2.
3.
4.
5.
6.
7.
8.
9.
"
1.
2.
2
r
3.
4.
5.
WHAT TO DO
When check is not OK refer to this columr
Replace any l&e terminals
and crimp to
leads.
Be sure male terminal blades are
straight and firmly connectedto mating part.
Clean circuit boardmale terminals. Replace
loose or damaged terminals. Securely recon-
nect leads.
Tighten terminal screws. Replace brushesif
leads are damaged.
See page 22.
Replace brushes. See page 22.
Replace spring if broken. Realign spring witb
brush. See page
22.
Clean brush holders. Remove carbon with
small cleaning brush. Align brush lead with
slot in brush holder to'assurefree vertical
brush movement.
Remove motor and have motor shop resur-
face commutator if possible. See page
30.
Replace motor. See page 30.
Replace bridge. See page 24.
Depress circuit breaker button toreset. if cil
trical Short", page16.
cuit breaker continuesto open, see "Elec-
Replace power supply cord. See page
23.
Replace ON/OFF switch. See page 23.
Replace jumper wire. See page 25.
Replace circuit breaker. See page 24.
(Continued)
Troubleshootingcontinued
on nextpage

YPE OF PROBLEM
ondition B
bntinued)
ondition
C
"
hen replacingthe bars prssaure wntml box C301l. remove thecircunbreaker.
dge, circuit board and alenrical hardware and reiMtall inthe new bars box.
hen
WHAT TO CHECK
If check Is OK, go to next check
6. Check motorthermal cutout switch.
Connect volt meterto TP6 female and TP9
female. Plug in and turn
on sprayer. Meter
should read 105 to 125 VAC. Turn
off and
unplug sprayer.
7. Check microswitch (3021. ReconnectTP6
connectors. Connect volt mater
to TP15
male and TP4. Meter should read50-125
VAC.
8. Visually inspect microswitch 13021 button.
Adjustment stud
(Q) should not depress the
microswitchbutton when fluid pressure is
zero. Manually check by depressingbutton
with small screwdriver; an audible clickin-
dicates microswitch is in normal position.
9. Check microswitch 1302) continuity withohm
meter. Be
sure sprayer is unplugged1 Mater
should read zero ohmswith
no fluid pressure
inthe sprayer.
10.Check all terminalsfor damage or loosefit.
Reconnect TP6 connectors.
11.Check circuit board
(23) by substitutingwith
a good board. See page25.
1.Check circuit board
(23) by removing from
25 for removal procedure.
box without disconnecting wires;
see page
while
still wired over-rides the optical detec-
WARNING: Removingthe circuit board
tor which could cause the sprayer to over-
tion properly. Turn the sprayer on
OML Y
pressurize, if the microswitch does not func-
shut
off immediately.
long enoughto check lamp condition, than
WARNING:To reduce the riskof electric
shock, handle board by
edges only1 Do not
allow any metal objectsto come in contact
with the boardl
Plug
in and turn on sprayer. Clear lamp
should
be on now - removing the circuit
board over-rides the optical detector. Turn
off and unplug sprayer.
2. Check bourdon tube flag and detector posi-
tion. Reinstall circuit board
(see page 251.
Turn pressure setting to maximum; flag
should extend
less than haif way into optical
detector slot from the bottom.
VIEW
OF OPTICAL DETECTOR AND FLAG
and reiMtall inthe new bars box.
box
C301l.
remove the circunbreaker.
WHAT TO DO
When checkle not OK refer to thls column
i. Allow motor to cool. Correct cause of over-
heating. If switch remains open etter motor
cools, check continuitybetween TP9 female
and TPlO with ohmmeter. If
open, replace
motor.
'. Clean microswitchmaleterminals.Replace
loose or damaged terminals. Securely recon-
nect leads.
I. Microswitchisfaulty. Return sprayer for
repair.
I. Microswitchisfaulty. Return sprayer for
repair.
0.Replace damaged terminals and reconnect
1.Replace circuit board.
See page 25.
securely.
. Replace circuit board. See page25.
!. Calibrate pressure controlto see if chat cor-
rects problem. See page 27.
If not, replace bare pressure control box
(3011'.Seepage
26.
Troubleshootingcontinued on nextpage

YPE OF PROBLEM
DW OUTPUT
0 OUTPUT
lotor run8 and pump stroke!
WHAT TO CHECK
Ifcheck is OK, go to next check
I. Check for worn spray tip.
2. Check to sae that pump does not continue
to stroke when gun trigger is released. Plug
in and turn
on sprayer. Prima with paint.
Trigger gun momentarily, then release and
engage safety latch. Relieve pressure, turn
off and unplug sprayer.
3. Check electrical supplywith volt meter.
Meter should read
105 to 125 VAC.
4. Check extension cord size and length: must
be at least 12 gaugewire and no longer thar
1Wft
(15.2 m).
5. Check G1 and G2 leads from bridge (308) to
circuit board
(23) for damage or lwae wires
or connectors. Refer to page
25.
Procedure on page 27.
5. Checkstaiipressure.Refer to Calibration
7. Check bridge (308) + and - iaadsand ter-
minalsto motor. InsDect wiring insulation
and terminalsfor signs of overheating.
See
page ,20.
3. Check for loose motor brush leads and tar-
mimls. See page
22.
8. Check for worn motor brushes which should
be 1
/2" minimum. See page 22.
I0.Check for broken and misaligned motor
brush springs. Rolled portion of spring must
rest squarely on top of brush.
I1.Check motor brushesfor binding
in brush
holders. Sea page
22.
12.Check circuit board (23) by substituting with
a good circuit board.
See page 25.
13.Check motor armaturefor shorts by using 81
armature tester (growler) or perform spin
test. See page 20.
14.Check bridge 1308) by substitutingwith a
gwdbridge or by performing the bridge
test.Seepage 19.
CAUTION: Do not performthis check until
armature is determined to be good. A bad
armaturewill immediately burn
out a good
bridge.
1. Check paintsupply.
2. Check for clogged intake strainer. See page
29.
3. Check for loose suction tubeor fittings. See
page 29.
WHAT TO DO
When check Is not OK refer to this colum
1. Follow PressureRelief Procedure Warn-
ingthen replace tip. See your separate gun
or tip manual.
2. Selvice pump.
See manual 307-793.
3. Reset building circuit breaker;replace
buildingfuse. Repair electrical outlet or try
another outlet.
4. Replacewith a correct, grounded extension
cord.
5. Clean circuitboard maleterminals.Replace
loosa or defective lead terminals. Securely
reconnect lead terminals to board.
6. Calibrate pressure control. See page 27.
7. Besure male terminal blades are centered
and firmly connected to female terminals.
Replace any loose terminal or damagedwir-
ing. Securely reconnect
wires to bridge.
8. lighten terminalscrews. Replacebrushes if
9. Replacebrushes. See page 22.
leads are damaged. See page 22.
10.Raplace spring if broken. Realign spring wit1
brush. See page Y2.
1l.Claan brush holders, remove carbon dust
with small cleaning brush. Align brush lead
with
slot in brush holderto assure free ver-
tical brush movement.
12.Replaca circuit board. See page
25.
13.Raplace motor. See page 30.
14.Replace bridge. See page 24.
1. Refilland reprimepump.
2.Removeandclean, then reinstall.
3. Tighten: use thread sealant or sealing tape
on threads if necessary.
Tmubleshooting continued on nextpage

TYPE OF PROBLEM
NO OUTPUT
(Continued)
notstroke
Motor
NnS but pump does
-
EXCESSIVE PRESSURE
FLUCTUATIONS
Spray patternvariations.
h
R
1
WHAT TO CHECK
If check Is OK, go to next check
ballare seating properly. See manual
m-793.
i. Check to sea if intake valve ball and piston
i. Check for leaking aroundthroat packing nut
which may indicate wornor damaged pack-
ings.See manual
307-793.
. Checkdisplacement pump connecting rod
pin. See page 28.
!. Check connecting rod assembly for damage.
I. Besure crank in drive housing rotates; plug
in sprayer and turn on momentarily to check.
Turn
off and unplugsprayer. Sea page 29.
sw page 28.
I. Be sureboth G1 and 62 leads from bridge
1308) to circuit board (231 erefirmly
connected. See page 25.
procedure on page 27.
!. Check stall pressure.Refer to Calibration
I. Check bourdontube flag and detector posi-
tion. Turn pressure setting tomaximum; flag
should not drag or
bind inoptical detector
slot of circuit board.
,-CIRCUIT BOARD
VIEWOFOPTICAL DETECTORAND FLAG
1. Check circuit board (23) by substituting with
i. Check LOW OUTPUT section on page 16.
a good board. See page 25.
I. Check tosee if sprayer has been operating at
low motor RPM and results in excessive heat
high pressure
with small tips, which causes
build up.
2. Check to see if ambient temperature where
sprayer is located is more than
90°F (32"Cl
or
if sprayer is located in direct sun.
3. Check to see if sprayer has been left ina
stalled condition (sprayer turned
on,
pressurized, but not operating1for long
periods of time.
Man replacing the bare pmsnure control box 1301). remove the circuit board, bridge.
circun board, and electrical hardware and reinstall in the MIW bare box.
WHAT TO DO
When check Is not OK refer to thls column
,. Remove intake valve and clean. Check balls
and matsfar nicks; replace if necessary. See
manual
307-793.
8. Replacepackings.Seemanual 307-793. Also
check piston valve seatfor hardened paint or
nicks and replace
if necessary.
. Replace pin if missing.Be sureretainer
spring isfully
in groove all around connact-
ing rod. See
28.
. Replace connecting rodassembly.Seepage
28.
. Check drive housing assemblyfor damage
and replace if necessary. See page 29.
. Reconnect securely. See page 24 and 25.
. Calibrate pressure control. See page 27.
. Carefully band flag into alignmentwith
detector slot
to sea if that corrects problem.
If
not, replace bare pressure control
assembly
1301)'. Calibrate pressure control
after reassembly.
. Replace circuit board. See page 25.
. Decrease pressure setting or increasetip
size.
:. Move sprayer to shaded, cooler area if
possible.
I. Turn off sprayer whenever you stop spraying
for
a while and relievefluid pressure.
Tmubleshooting continuedonnexrpage

ELECTRICAL SHORT
Buildingcircuit breaker opens
turned
on.
as soon as sprayer switch is
Any short in any part of tht
CAUTION
motorpowercircuit, which i:
connected to the output sidt
of the bridge, will causetht
bridge to burn out immediats
ly.Correctlydiagnosean(
repair
all shorts before check
ing and replacing bridge
as soon es sprayer is plugged
Buildingcircuit breaker opens
turned
on.
into outlet and sprayer is NO
after sprayer operatesfor
on1
Sprayer circuit breaker opens
6 to 10 minutes.
-
WHAT TO CHECK
Ifcheck i. OK, eo to nextcheck1
I. Check a11 electrical wiring for damaged in-
sulation, and
all terminals for loose fit or
damage. Be sure to check wires between
pressure control and motorwhich ere ences-
ed in conduit (22). Seepege 29.
1. Check for missing inspection plate gasket
(see page
22). bent terminal forks or other
metalto metalcontact pointswhich could
cause
e short.
3. Check motor armaturefor shorts by usingan
test. See page 19. Inspect windings for
armature tester (growler)or perform spin
burns.
1. Check bridge (308) by substitutingwith a
good bridgeor by performing bridge test.
See page 20.
CAUTION: Do not performthis check until
armature is determined to be good. A bad
armature
will immediatelybum out a good
bridge.
1. Check'BasicElectricalProblems' on page 14
2. Check ONlOFF switch (303) Seepage 23.
Be sum the sprayer is unplugged1 Disconnec
wires from switch and check switchwith
ohm meter. The ohm meter should read in-
with the switch ON.
finity
with the ON/OFF switch OFF, and zerc
burn the bridgeoutimmediately, whichin turi
CAUTION: A short in the motor circuitwil
usually ceusesthe ON/OFFswitchtofail
in thl
closed mode.
1. Check electrical supplywith volt meter.
Meter shouldread
105 to 125 VAC.
2. Check tightness of pump packing nut. Over-
tightening nut tightens packings
on rod,
restricts pumpaction, and damages
- packings. See page 28.
3. Check stall pressure.Remove the plug from
the top of the fluid filter, and install
a 5ooo
psi (350 bar) fluid-filled pressure gauge. See
Age 27. Plug inand turn on sprayer. Slowly
increase pressure setting to maximum.
PumF
Turn off and unplug sprayer.
should
stall at 2560-2750 psi 1178195 bar).
system, reatcircuit breaker button.
4. After determining that there is no short in
WHATTO DO
When ckk le not OK refer to this columr
1. Repair or replace any damaged wiring or ter-
minals. Securely reconnect
all wires.
2. Correct faulty conditions.
3. Replace motor. See page 30.
4. Replace bridge. See page 24.
2. Replace ONlOFF switch. See page 23.
1. If voltage is too high,, do not operate sprayel
until corrected.
2. Loosen packingnut.Check for leaking
around throat.Replace pump packings, if
nBcB8881y. Seemanual 307-753.
3. Calibrate pressure control. See page 27.
4. If circuit breaker continues to open (button
pops up), replace the circuit breaker. See
page 24.
Troubleshootingcontinued on nextpage
18 307-758

the risk of a fluid injection injury, injuryfrom mov-
ing Darts. or electric shock.
trical continuity.
For checking armature, motor'windingand brush elec-
setup
Remove the drivehousing from the sprayerasdas-
cribed in "DriveHousingReplacement",Steps
14,
page 29.
Remove the pressure control coverandscrews, the
covers
IJ). See Fig 10.
motor cover, thefan cover IF), and the inspection
Disconnect the
two leads from the motorto the bridge
Armature
Short Clrcult Test
shorts, the motor will coast two or threerevolutions
Quickly turn themotor
fan by hand. If them are no
before comingtoa complete stop.
If themotor does not spin freely and resists rotation,the
armatureisshortedandthe motor mustbereplaced.
See page
30.
1308). see Fig 11.
Armature, Brushes, andMotorWlrlng Open
Clrcult Test (Continuity)
Connect the
two black motor leads togetherwith a test
lead.
Turn the motor fan by hand at about
two revolutions
per second.
following: a)brokenbrushsprings; b) brokenbrush
If there is unevenor no turning resistance,check the
leads;
c) loose brush terminal screws; d) worn brushes;
e) broken motor leads; f) loose motorleadterm@als.
Repair partsas
needed. See page 22.
If there is still uneven or no turning resistance, replace
the motor. See page
30.

~ ~~
BRIDGE TEST
Remove the bridge from the pressure control box and
performthistest todetermine
if thebridgeisfunctional.
See Bridge Rectlfler Replacement, page 24. Use a
continuity tester,such as multi-meterset on the X1
ohmsscale ( IY ).
Eight individualchecks, or tests, mustbe performed.If
the bridge fails even one test,
it mustbe replaced.
Fig 12 showstheposition of the wires on the bridge. Us-
ingthe chartat the right, connectthe meterwires sa in-
dicatedbythe black dotsfor each test, then check the
continuity.
In
Tests 1,2 and 3, there should be NO continuity.
In Tests 4,5 and 6, connect the + and - meter wiresas
indicated, check continuity, thenswitchthe meter wire
connectionsandcheckc0ntinu.Wagain.You should
get
NO continuity oneway,andYES continu'wthe
other way.
In
Tests 7 and 0. connect themeter wires asindicated
bythe black dots. Touch the indicated
"G" wiretoone
meter wire, and then to the other. You should get
NO
continuityone way, andYES continuity the otherway.
BRIDGE
WIRES